2AZ-FE Cooling CO 1-35
2AZ-FE Cooling CO 1-35
2AZ-FE Cooling CO 1-35
COOLING SYSTEM
ON-VEHICLE INSPECTION
1. CHECK COOLING SYSTEM FOR LEAKS
(a) Remove the radiator reservoir cap.
CAUTION:
To avoid the danger of being burned, do not
remove the radiator reservoir cap while the
engine and radiator are still hot. Thermal
expansion will cause hot engine coolant and
steam to blow out from the radiator reservoir.
(b) Fill the radiator and reservoir with coolant, and then
Radiator Cap Tester
attach a radiator cap tester.
(c) Warm up the engine.
(d) Pump the radiator cap tester to 118 kPa (1.2 kgf/
cm2, 17.1 psi), and then check that the pressure
does not drop.
If the pressure drops, check the hoses, radiator and
water pump for leakage.
If there are no signs of external coolant leaks, check
A112194E01
the heater core, cylinder block and head.
(e) Reinstall the radiator reservoir cap.
2. CHECK ENGINE COOLANT LEVEL OF RESERVOIR
(a) The engine coolant should be between the LOW
and FULL lines when the engine is cold.
If low, check for leakage and add TOYOTA Super
Long Life Coolant (SLLC) or similar high quality
ethylene glycol based non-silicate, non-amine, non-
nitrite, and non-borate coolant with long-life hybrid
organic acid technology up to the FULL line.
A112306
3. CHECK ENGINE COOLANT QUALITY CO
(a) Remove the radiator reservoir cap.
CAUTION:
To avoid the danger of being burned, do not
remove the radiator reservoir cap while the
engine and radiator are still hot. Thermal
expansion will cause hot engine coolant and
steam to blow out from the radiator.
(b) Check for any excessive deposits of rust or scale
around the radiator reservoir cap and radiator filler
hole; the coolant should be free of oil.
If excessively dirty, replace the coolant.
(c) Install the radiator reservoir cap.
CO–2 2AZ-FE COOLING – COOLING FAN SYSTEM
PARTS LOCATION
CO
A114322E04
2AZ-FE COOLING – COOLING FAN SYSTEM CO–3
SYSTEM DIAGRAM
FAN L
FAN NO. 3
FAN H
FAN NO. 2
No. 2 Cooling
Fan Motor
from RDI H-Fuse CO
FAN NO. 1
E1
No. 1 Cooling Fan Motor
A112331E01
CO–4 2AZ-FE COOLING – COOLING FAN SYSTEM
ON-VEHICLE INSPECTION
HINT:
It is normal for the cooling fan to sometimes rotate when the
ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION AT LOW
TEMPERATURES (Below 94°C (201°F))
(a) Turn the ignition switch ON with the A/C switch OFF.
(b) Check that the cooling fan stops.
If it does not, check the cooling fan relays and
engine coolant temperature sensor, and then check
for disconnection of the connector or a wire break
between the cooling fan relay and engine coolant
temperature sensor.
A127842
A112176
A127843
CO
CO–6 2AZ-FE COOLING – COOLANT
COOLANT
REPLACEMENT
1. REMOVE NO. 1 ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
(a) Loosen the radiator drain cock plug.
HINT:
Collect the coolant in a container and dispose of it
according to the regulations in your area.
(b) Remove the radiator reservoir cap.
CAUTION:
Do not remove the radiator reservoir cap while
the engine and radiator are still hot.
Pressurized, hot engine coolant and steam may
be released and cause serious burns.
(c) Loosen the cylinder block drain cock plug.
Radiator Reservoir
CO
CO
2AZ-FE COOLING – WATER PUMP CO–9
WATER PUMP
2AZ-FE COOLING
ENGINE
COMPONENTS
96 (979, 71)
96 (979, 71)
52 (530, 38)
21 (215, 16)
GENERATOR ASSEMBLY
A114338E04
CO–10 2AZ-FE COOLING – WATER PUMP
CLAMP BRACKET
26 (265, 19)
CO
A114324E03
2AZ-FE COOLING – WATER PUMP CO–11
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE NO. 1 ENGINE UNDER COVER
3. REMOVE FRONT FENDER APRON RH
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. DRAIN ENGINE COOLANT (See page CO-6)
6. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
7. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
8. REMOVE GENERATOR ASSEMBLY (See page CH-9)
9. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 4 bolts and water pump
pulley.
SST SST 09960-10010 (09962-01000, 09963-00700)
A098715E03
A094516E01
Clamp Bracket
B012052E03
CO–12 2AZ-FE COOLING – WATER PUMP
Pry
B012053E04
INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump
assembly.
(b) Turn the pulley, and then check that the water pump
bearing moves smoothly without making a "click"
noise.
A112198
If it does not move smoothly, replace the water
pump assembly.
CO
2AZ-FE COOLING – WATER PUMP CO–13
INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Remove any old seal packing material from the
contact surface.
(b) Apply a continuous line of seal packing as shown in
the illustration.
Seal packing:
Seal Diameter:
2.2 to 2.5 mm Toyota Genuine Seal Parking Black, Three
A A Bond 1207B or equivalent
Standard seal diameter:
2.2 to 2.5 mm (0.09 to 0.10 in.)
NOTICE:
• Remove any oil from the contact surface.
• The parts must be set within 3 minutes after
applying seal packing. Otherwise, the
material must be removed and reapplied.
(c) Install the water pump and clamp bracket with the 4
A-A bolts and 2 nuts.
0.5 to 1.0 mm Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(0.02 to 0.04 in.) (d) Install the wire of the crankshaft position sensor
onto the clamp bracket.
(e) Install the clamp of the crankshaft position sensor
onto the water pump.
2.5 mm (0.10 in.)
A094495E03
THERMOSTAT
2AZ-FE COOLING
ENGINE
COMPONENTS
GASKET
THERMOSTAT
WATER INLET
CO
Non-reusable part
A114317E03
2AZ-FE COOLING – THERMOSTAT CO–15
REMOVAL
1. REMOVE NO. 1 ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT (See page CO-6)
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. DISCONNECT NO. 2 RADIATOR HOSE
5. REMOVE WATER INLET
(a) Remove the 2 nuts and disconnect the water inlet
from the cylinder block.
6. REMOVE THERMOSTAT
(a) Remove the gasket from the thermostat.
A112181
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The valve opening temperature is inscribed on the
thermostat.
P013560E01
P000436E01
INSTALLATION
1. INSTALL THERMOSTAT
(a) Install a new gasket onto the thermostat.
(b) Install the thermostat with the jiggle valve upward.
Upward HINT:
The jiggle valve may be set to within 10° on either
10° 10°
side of the prescribed position.
Jiggle Valve
A112199E02
CO
2AZ-FE COOLING – COOLING FAN MOTOR CO–17
COMPONENTS
BATTERY CLAMP
BATTERY
RADIATOR SUPPORT OPENING COVER
CO
RADIATOR GRILLE
SUB-ASSEMBLY
HORN CONNECTOR
19 (194, 14)
CO
A114319E02
2AZ-FE COOLING – COOLING FAN MOTOR CO–19
19 (194,14)
10.5 (107, 8)
COOLER CONDENSER
RADIATOR ASSEMBLY
FAN SHROUD
CUSHION
CO
A114320E05
CO–20 2AZ-FE COOLING – COOLING FAN MOTOR
FAN SHROUD x3 x3
FAN
FAN
A114316E03
2AZ-FE COOLING – COOLING FAN MOTOR CO–21
ON-VEHICLE INSPECTION
1. INSPECT NO. 1 COOLING FAN MOTOR
(a) Disconnect the No. 1 fan connector.
(b) Connect the battery and ammeter to the No. 1 fan
motor connector.
(c) Check that the No. 1 fan rotates smoothly, and then
check the reading on the ammeter.
Standard amperage
Indication Mark Motor Type Condition Specified
Condition
B, C 160 W At 20°C (68°F) 11.7 to 14.7 A
HINT:
: Indication Mark
Refer to the illustration for the indication mark
A127844E01 location.
If the result is not as specified, replace the No. 1
cooling fan motor.
(d) Reconnect the No. 1 fan motor connector.
2. INSPECT NO. 2 COOLING FAN MOTOR
(a) Disconnect the No. 2 fan connector.
(b) Connect the battery and ammeter to the No. 2 fan
motor connector.
(c) Check that the No. 2 fan rotates smoothly, and then
check the reading on the ammeter.
Standard amperage
Indication Mark Motor Type Condition Specified
Condition
B 120 W At 20°C (68°F) 8.4 to 10.4 A
C 160 W At 20°C (68°F) 11.7 to 14.7 A
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator (see page CO-29).
DISASSEMBLY
1. REMOVE FAN
(a) Remove the 2 nuts and 2 fans.
A112341
CO REASSEMBLY
1. INSTALL NO. 2 COOLING FAN MOTOR
(a) Install the fan motor with the 3 screws.
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
2. INSTALL NO. 1 COOLING FAN MOTOR
(a) Install the fan motor with the 3 screws.
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
No. 2 Fan Motor No. 1 Fan Motor
A112342E01
3. INSTALL FAN
(a) Install the 2 fans with the 2 nuts.
Torque: 6.3 N*m (64 kgf*cm, 55 in.*lbf)
(b) Check the fan motor operation.
A112341
2AZ-FE COOLING – COOLING FAN MOTOR CO–23
INSTALLATION
1. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-32).
2. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
3. ADD ENGINE COOLANT (See page CO-6)
4. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
CO
2AZ-FE COOLING – COOLING FAN RELAY CO–23
1 2
3
3-4 Below 1 Ω CO
3-5 10 Ω or higher
3-4 10 Ω or higher
A087121E01
(when battery voltage is applied to
terminals 1 and 2)
3-5 Below 1 Ω
(when battery voltage is applied to
terminals 1 and 2)
CO
2AZ-FE COOLING – RADIATOR CO–25
RADIATOR
2AZ-FE COOLING
ENGINE
COMPONENTS
BATTERY CLAMP
BATTERY
RADIATOR SUPPORT OPENING COVER
CO
RADIATOR GRILLE SUB-ASSEMBLY
HONE CONNECTOR
19 (194, 14)
CO
A114319E05
2AZ-FE COOLING – RADIATOR CO–27
19 (194,14)
10.5 (107, 8)
COOLER CONDENSER
RADIATOR ASSEMBLY
FAN SHROUD
CUSHION
CO
A114320E06
CO–28 2AZ-FE COOLING – RADIATOR
ON-VEHICLE INSPECTION
1. CHECK RADIATOR RESERVOIR CAP SUB-
ASSEMBLY
(a) Measure the valve opening pressure.
(1) If there are water stains or foreign matter on O-
ring 1, clean it with water and finger scouring.
2 (2) Check that O-ring 1 is not deformed, cracked or
swollen.
(3) Apply engine coolant to O-ring 1 and rubber
1 A112200
packing 2 before using a radiator cap tester.
(4) When using the cap tester, tilt it more than 30
Reservoir Cap degrees.
Radiator Cap Tester (5) Pump the cap tester several times, and check
the maximum pressure*.
Pump speed:
1 pump per second
*: Even if the cap cannot maintain the
maximum pressure, it is not a defect.
Judgment criterion
Item Specified Condition
30° or more
Standard value 93.3 to 122.7 kPa (0.95 to 1.25 kgf/
(for brand-new cap) cm2, 13.5 to 17.8 psi)
Minimum standard value 78.5 kPa (0.8 kgf/cm2, 11.4 psi)
(after using cap)
A110393E01
If the maximum pressure is less than the
minimum standard value, replace the radiator
reservoir cap sub-assembly.
ON-VEHICLE CLEANING
1. INSPECT RADIATOR ASSEMBLY
(a) Check that the radiator and condenser are not
CO blocked with leaves, dirt, or insects. Clean the hose
connections.
If the fins are blocked, wash them with water or a
steam cleaner.
NOTICE:
A112201
• If the distance between the steam cleaner and
core is too close, the fins may be damaged.
• Keep the following injection distance.
Standard injection distance
Injection Pressure Specified Condition
2,942 to 4,903 kPa 300 mm (11.81 in.)
(30 to 50 kgf/cm2, 427 to 711 psi)
4,903 to 7,845 kPa 500 mm (19.69 in.)
(50 to 80 kgf/cm2, 711 to 1,138 psi)
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE BATTERY CLAMP
(a) Remove the bolt, nut and clamp.
4. REMOVE BATTERY
5. REMOVE NO. 1 ENGINE UNDER COVER
6. DRAIN ENGINE COOLANT (See page CO-6)
7. REMOVE RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-6)
8. DISCONNECT HOOD LOCK SWITCH CONNECTOR
CO
No. 5 Water By-pass Hose No. 1 Water By-pass Pipe No. 1 Water By-pass Hose
A112333E01
A114326
CO
A112185
A112186
2AZ-FE COOLING – RADIATOR CO–31
No. 1 Radiator Hose No. 2 Radiator Hose No. 2 Water By-pass Hose
A112334E01
A114339
CO–32 2AZ-FE COOLING – RADIATOR
A114328
INSTALLATION
1. INSTALL FAN SHROUD WITH COOLING FAN
(a) Install the fan shroud with cooling fan with the 2
bolts to the radiator.
Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf)
2. INSTALL RADIATOR ASSEMBLY
(a) Install the 4 fan shroud cushions to the cooler
condenser.
A114328 (b) Set the cooler condenser to the fan shroud.
A114339
A112338
A112186
2AZ-FE COOLING – RADIATOR CO–33
Upper Upper
LH Side LH Side
A B
No. 1 Radiator Hose No. 2 Radiator Hose No. 2 Water By-pass Hose
CO
A A
B
A
A
A A
A112335E01
A114326
A B C
B A
No. 5 Water By-Pass Hose No. 1 Water By-Pass Pipe No. 1 Water By-Pass Hose
A114357E01